MECHANICAL ENGINEERING DEPARTMENT

DJJ10033
WORKSHOP
TECHNOLOGY
UNIT 4
Milling machine
 LEARNING OUTCOME
After studying this topic student will be able to:
1. Compare types of milling machine.
2. Explain the characteristics and parts of universal milling
machine.
3. State the basics principles of milling machine (X,Y and Z
axis).
4. Sketch the two methods of up cut and down cut milling.
5. Explain the usage of various types of milling cutter.
6. Sketch various types of milling cutter.
7. Explain methods of holding cutting tools.
8. Explain methods of holding work piece.
9. Calculate the revolution per minute (rpm), feed rate and
cutting time.
10. Apply the safety procedures while using the milling machine.
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Introduction
• Definition: milling machine is a machine tool that
removes metal as the work is fed against rotating
multi-tooth cutting tool. (v1)

• Multi-tooth cutting tool which is called a milling cutter

and cutting edge called teeth.

• Milling is one of the basic machining processes that

allows large amount of the material to be removed
quickly.(v2)

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Introduction
• Milling is very versatile process capable of
producing simple two dimensional flat shape to
complex three dimensional interlaced surface
configuration.

• There are several type of operation could be done

using milling machine which are; slab milling,
slotting, side milling, straddle milling, form milling,
face milling, end milling, profile milling, pocket
milling, and 3-dimensional surface milling.

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Types of milling machine
Types Of Milling Machine

Planar Type Special Type

Column and Knee Type Milling Milling Milling
Machine Machine Machine

Horizontal Vertical

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Types of milling machine
Planar Type
Milling
Machine

Special
Type Milling
Machine
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Horizontal milling machine

• is designed to hold
the cutting tool and
rotate it on a
horizontal axis

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Horizontal milling machine
Y– AXIS (Knee)

- The Y+ (positive) means motioning UP and

TOWARDS from cutter.

- The Y- (negative) means motioning DOWN and

AWAYS the cutter.

Z– AXIS (Saddle ; moves front to back)

- The Z+ (positive) means motioning TOWARDS

the operator
- The Z- (negative) means motioning AWAYS the
operator

X – AXIS (Table ; moves left and right

- The X+ (positive) means motioning to the LEFT

- The X- (negative) means motioning to the RIGHT

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VERtical milling machine

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VERtical milling machine
Z – AXIS (Tool located)

- The Z+ (positive) means motioning UP and AWAY

from workpiece table.

- The Z- (negative) means motioning DOWN and

TOWARDS the workpiece/table.

Y – AXIS (Saddle ; moves front to back)

- The Y+ (positive) means motioning TOWARDS

the operator
- The Y- (negative) means motioning AWAYS the
operator

X – AXIS (Table ; moves left and right

- The X+ (positive) means motioning to the LEFT

- The X- (negative) means motioning to the RIGHT

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Parts of milling machine
Part Function
Base  It a foundation member for all the others parts, rest on it.
 Column attached on it, and may contain coolant reservoir.

Column  Main supporting mounted vertically on the base.

Knee  The knee supports the saddle and the table.

 The knee can be moved up and down for workpiece positioning.

Saddle  The saddle it attached to the knee.

 The saddle provides the in and out, or Y axis travel of the table.

Table  Holds and secures the workpiece for machining.

Overarm  Used on horizontal machines.

 It adjustable to accommodate differents arbor length.

Spindle  The spindle holds the tool and provides the actual tool rotation.

Arbor  Its like an extension of the machine spindle on which milling cutter
are securely mounted and rotated.

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milling method

Milling Method

Up Milling / Down Milling /

Conventional Milling Climb Milling

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Up milling method
Up Milling

• Also called conventional milling

• Wheel rotation opposite of the feed

• The chip formed by each cutter tooth starts out very thin and increases its
thickness

• The length of the chip is relatively longer

• Tool life is relatively shorter

• Need more clamping force to hold the work part still.

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Down milling method
Down Milling

• Also called climb milling

• Wheel rotation is parallel to the feed

• The chip formed by each cutter tooth starts out thick and leaves out thin

• The length of the chip is relatively short

• Tool life is relatively longer

• Need less clamping force to hold the work part still.

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Advantages Down milling method

• It discards the surface burrs.

• It gives smooth cut.

• It suitable for milling thin and flexible

materials.

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Milling Cutter
Milling cutter are made in various forms to
perform certain classes of work, and may be
classified as:-
1) Plain milling cutter
2) Side milling cutter
3) Angle milling cutter
4) Slitting saw
5) Formed milling cutter
6) T-slot cutter
7) End milling cutter
8) Dove tail mill
9) Two fluted end mill
10) Four fluted end mill
11) Corner round mill
12) Ball end mill 16
Milling Cutter
Types of Milling Cutter Description

Plain Milling Cutter • Also known as mill cutter

• The shape like a disc and having

cutter teeth on its circumference

• Two types of plain milling cutter

1. Plain straight teeth cutter
2. Plain milling helical cutter
Side Milling Cutter • Are essentially plain milling cutters
with the addition of teeth on one or
both sides

• Used for side milling and slot cutting

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Milling Cutter
Types of Milling Cutter Description

Angle Milling Cutter • The cutter may be single or double

angle cutter

• The cutting edges are form at the

conical surface around the periphery
of the cutter.

Slitting Saw • These are very thin cutter

• Varying thickness for 0.5 mm to 5

mm

• Used for cutting deep slots and

parting off materials into pieces

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Milling Cutter
Types of Milling Cutter Description

Formed Milling Cutter • Cutter designed to cut definite shape

• Can be classified according to the

shape as convex or concave

T-slot Cutter • Special form of end mill for making T-

slot

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Milling Cutter
Types of Milling Cutter Description

End Milling Cutter • These cutter have teeth on its end

• Used for milling flat surface, milling

slots and profiles.

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Milling Operation
There are several milling operation classified as
follow:-
1. Plain / Slab milling
2. Face milling
3. Angular milling
4. Straddle milling
5. End milling
6. T-slot milling

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Plain Milling
• Operation
 Process to get the flat surface on the
workpiece in which cutter axis and
workpiece axis is parallel

• Milling cutter : Plain milling cutter

• Machine : Horizontal Miliing Machine

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face Milling
• Operation
 Process to get flat surface, which is
perpendicular to the axis of rotating cutter

• Milling cutter : Face milling cutter

• Machine : Vertical Milling Machine

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Angular Milling
• Operation
 Process to produce all angular cuts like V-
notches and grooves and angular surfaces.

• Milling cutter : Double angle milling cutter

• Machine : Horizontal Milling Machine

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Straddle Milling
• Operation
 Operation of machining two parallel
surfaces simultaneously on a workpiece.

• Milling cutter : 2 or more side and face milling

cutter

• Machine : Horizontal Milling Machine

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End Milling
• Operation
 Operation performed for producing flat
surface, slot, grooves or finishing the edges
of the workpiece.

• Milling cutter : End Milling Cutter

• Machine : Vertical Milling Machine

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T-slot Milling
• Operation
 Operation perfomed to produce T-slot

• Milling cutter : T-Slot Milling Cutter

• Machine : Vertical Milling Machine

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Milling Workholding
Before start the milling operation, its important to
ensure the workpiece securely fastened to table
machine. There are several methods of holding a
workpiece:-

a) Plain vises

b) Swivel base vise

c) Universal vise

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Milling Workholding
Plain vise

Jaws parallel or 90º to axis of spindle

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Milling Workholding
Swivel base vise

Can swivel through 360º in horizontal

plane

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Milling Workholding
Universal Vise

Can swivel through 360º in horizontal

plane and tilted from 0º to 90 in
vertical plane.

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Milling Cutter Holding Devices
• The following devices are commonly used for
mounting milling cutter on spindle
1. Arbor
• Cutter having a bore are mounted on the
arbor of milling machine
2. Collet
• Just a types of sleeve used for reducing
the size of taper with tapper shank
3. Adapter
• Is also form of the collet used on milling
machine having standard spindle end

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Milling Cutter Holding Devices

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Milling Cutter Holding Devices

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Machining time
1. Spindle Speed - N v (rpm)
• v = cutting speed N
• D = cutter diameter
πx D
2. Feed Rate - fr
• f = feed per tooth
f r  N x nt x f (mm/min)
• nt = number of teeth

3. Machining Time - Tm
L  d  D - d ( (min)
1. Plain/Slab Milling:
• L = length of cut
Tm L  D
• d = depth of cut Tm  fr
2. Face Milling: fr
L  D L  2 wD - w
• w = width of cut T  -or- Tm 
MRR f rw d fr
• 2 form is multi-pass m
nd
fr

4. Materiall Removal Rate - MRR MRR  w d fr (mm3/min)

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Machining time – plain
milling
𝐿𝑗 = 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑡ℎ𝑒 𝑗𝑜𝑏 𝑡𝑜 𝑚𝑎𝑐ℎ𝑖𝑛𝑒𝑑, 𝑚𝑚
𝑙1 = 𝑎𝑝𝑝𝑟𝑜𝑎𝑐ℎ, 𝑚𝑚
𝑙2 = 𝑜𝑣𝑒𝑟𝑟𝑢𝑛 𝑜𝑓 𝑡ℎ𝑒 𝑐𝑢𝑡𝑡𝑒𝑟, 𝑚𝑚
𝐷 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑐𝑢𝑡𝑡𝑒𝑟, 𝑚𝑚
𝑑 = 𝑡𝑜𝑡𝑎𝑙 𝑑𝑒𝑝𝑡ℎ 𝑜𝑓 𝑐𝑢𝑡, 𝑚𝑚
𝐿 = 𝑙1 + 𝐿𝑗 + 𝑙2
𝑙1 = 𝑑(𝐷 + 𝑑) , 𝑚𝑚

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Machining time – face
milling
𝐿𝑗 = 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑡ℎ𝑒 𝑗𝑜𝑏 𝑡𝑜 𝑚𝑎𝑐ℎ𝑖𝑛𝑒𝑑, 𝑚𝑚
𝑙1 = 𝑎𝑝𝑝𝑟𝑜𝑎𝑐ℎ, 𝑚𝑚
𝑙2 = 𝑜𝑣𝑒𝑟𝑟𝑢𝑛 𝑜𝑓 𝑡ℎ𝑒 𝑐𝑢𝑡𝑡𝑒𝑟, 𝑚𝑚
𝐷 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑐𝑢𝑡𝑡𝑒𝑟, 𝑚𝑚
𝑑 = 𝑡𝑜𝑡𝑎𝑙 𝑑𝑒𝑝𝑡ℎ 𝑜𝑓 𝑐𝑢𝑡, 𝑚𝑚
𝐿 = 𝑙1 + 𝐿𝑗 + 𝑙2
𝑙1 = 0.5 (𝐷 − 𝐷2 − 𝐵2 ) , 𝑚𝑚
𝐵 = 𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 𝑗𝑜𝑏, 𝑚𝑚
𝐿+𝐷
𝑇𝑚 = , min
𝑓𝑟

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Example plain milling

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Example face milling

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Safety procedure while using the milling machine
1. Be sure work and cutter are mounted securely before taking cut
2. Always wear safety glasses
3. When mounting or removing milling cutters, always hold them with
cloth to avoid being cut
4. When setting up work, move table as far as possible from cutter to
avoid cutting your hands
5. Be sure cutter and machine parts clear work
6. Never attempt to mount, measure, or adjust work until cutter
completely stopped
7. Keep hands, brushes, and rags away from revolving milling cutter
at all times
8. Do not use an excessively heavy cut or feed cause cutter to break
and fly apart
9. Keep floor around machine free from chips, oil, and cutting fluid.

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Past Year Final Exam Question
June 2018
Question (2)(c)
Calculate the feed rate in mm/min for a 14 tooth HSS end
mill cutter with a diameter of 60mm with cutting speed of 98
m/min. Use the value of feed per tooth of 0.06mm.

December 2018
Question (2)(c)
Calculate the feed rate in mm/min for a 12 tooth helical
carbide milling cutter with diameter of 50mm for machining
a cast iron work piece (CS33). Use the value of chip per
tooth CPT of 0.06.

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